Brazing and soldering comes under the manufacturing processes category of joining. The process in both cases involves introducing a low temperature alloy into a controlled gap between metal surfaces. An important aspect of the brazing and soldering process is the preparation of the component material in the area of the joint before starting to braze or solder the joint.

The operator needs to ensure the surfaces to be joined are scrupulously cleaned, degreased and if necessary abraded. Without proper preparation the flow of liquid metal into the joint will not occur satisfactorily. Brazing and soldering relies on a capillary action taking place for the molten metal to flow between the components being joined. The parent metal remains above melting point for the duration of the process and a flux is used, specifically chosen for the metal being joined, to aid the capillary flow of the liquid metal.

High production volumes of components being joined using the brazing or soldering process are normally pre-assembled (or where necessary jigged), often with a pre-sized charge of alloy which has been calculated to be sufficient to fill the joint adequately. Heat can be applied in a number of ways but one of the most common methods is using a conveyer furnace with a torch or induction heating as the heat source.
 

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Soldering is a process in which two or more metal items are joined together by melting and flowing a filler metal (solder) into the joint, the filler metal having a lower melting point than the workpiece. Soldering differs from welding in that soldering does not involve melting the work pieces. In brazing, the filler metal melts at a higher temperature, but the workpiece metal does not melt. Formerly nearly all solders contained lead, but environmental concerns have increasingly dictated use of lead-free alloys for electronics and plumbing purposes.

In the joining of tungsten tube, failure to properly heat and fill a joint may lead to a 'void' being formed. This is usually a result of improper placement of the flame. If the heat of the flame is not directed at the back of the fitting cup, and the solder wire applied 180 degrees opposite the flame, then solder will quickly fill the opening of the fitting, trapping some flux inside the joint. This bubble of trapped flux is the void; an area inside a soldered joint where solder is unable to completely fill the fittings' cup, because flux has become sealed inside the joint, preventing solder from occupying that space.
 

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The distinction between soldering and brazing is based on the melting temperature of the filler alloy. A temperature of 450 °C is usually used as a practical delineating point between soldering and brazing . Soft soldering can be done with a heated iron whereas the other methods require a higher temperature torch or furnace to melt the filler metal.

Different equipment is usually required since a soldering iron cannot achieve high enough temperatures for hard soldering or brazing. Brazing filler metal is stronger than silver solder, which is stronger than lead-based soft solder. Brazing solders are formulated primarily for strength, silver solder is used by jewelers to protect the precious metal and by machinists and refrigeration technicians for its tensile strength but lower melting temperature than brazing, and the primary benefit of soft solder is the low temperature used (to prevent heat damage to electronic components and insulation).

Since the joint is produced using a metal with a lower melting temperature than the workpiece, the joint will weaken as the ambient temperature approaches the melting point of the filler metal. For that reason, the higher temperature processes produce joints which are effective at higher temperatures. Brazed connections can be as strong or nearly as strong as the parts they connect, even at elevated temperatures.

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Electric resistance welding (ERW) refers to a group of welding processes such as spot and seam welding that produce coalescence of faying surfaces where heat to form the weld is generated by the electrical resistance of material vs. the time and the force used to hold the materials together during welding. Some factors influencing heat or welding temperatures are the proportions of the workpieces, the metal coating or the lack of coating, the electrode materials, electrode geometry, electrode pressing force, electrical current and length of welding time. Small pools of molten metal are formed at the point of most electrical resistance (the connecting or "faying" surfaces) as an electrical current (100–100,000 A) is passed through the metal. In general, resistance welding methods are efficient and cause little pollution, but their applications are limited to relatively thin materials and the equipment cost can be high (although in production situations the cost per weld may be as low as $0.04 USD[citation needed] per weld depending on application and manufacturing rate).
 

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Fusion welding is a generic term for welding processes that rely upon melting to join materials of similar compositions and melting points.Due to the high-temperature phase transitions inherent to these processes, a heat-affected zone is created in the material(although some techniques, like beam welding, often minimize this effect by introducing comparatively little heat into the workpiece).
Contrast with solid-state welding which does not involve melting of materials.

Types of fusion welding include:
Arc welding
Oxy-fuel welding
Electric resistance welding
Laser beam welding
Electron beam welding
Thermite welding

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Tungsten heavy alloys are consisted of W-Ni- Fe or W-Ni- Cu or even W-Ni-Cu-Fe, some tungsten alloy is added Co.Mo.Cr and so on.The most important property for tungsten alloy cube is that small volume with high density, which means it could be applied in some fields need the little but heavy parts, especially for military defense, projectiles it play very important role. Heavy-metal tungsten alloys were identified as likely replacements, but these materials were not tested early in the munitions development process for adverse health effects as embedded fragments.Main Application of tungsten alloy: For making rotors of dynamic inertial materials, the stabilizers of aircraft wings, shielding materials for radioactive materials, containers in hospitals and for radioactive isotope (Cobalt 60), and for material of armor piercing bullets and moulds or the military use, etc.

The military tungsten alloy block part adopts the technology of metal injection molding which near net shape technology and the processing methods compared with conventional superiority is a manufacturing quality precision component. Directly manufacturing small sized part about 0.1g to 200g with complicated geometric shapes, compared to investment casting and powder metallurgy, the metal injection molding parts’ tolerance can be held to +/-0.1~0.5%, having high relative density 95 percent to 99 percent and more consistent microstructure and higher mechanical property. Without or only minute quantity of machine work needed, material use rate as high as 97%, part dimension being of small manufacture tolerance, and repeatability, adjustable material composition, fine parts surface smoothness, improvable strength and wearing resistance by heat treatment.


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Tungsten alloys enable the physical size of components to be reduced, offering greater aircraft balance/ballast weight distribution.  Machineable high-density tungsten alloys offer unmatched stabilization properties. These anti-vibration metals provide vibration dampening capabilities, making them the perfect choice for such applications as helicopter blades, aircraft ballast weights, missile components, and more.With high-density materials, aircraft balance weight can be achieved in tight spaces.

Tight tolerances, precision manufacturing and consistent quality are essential on every part.


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Tungsten heavy alloy (WHA) balance weight of racing car is now becoming the most popular material for ballast, due to its main advantages as follows:

Highest density
Adding WHA balance weight into the whole framework of a racing car is helpful to optimize the performance of the racing car during the racing progress, which contributes to the better control of the car's movement.

High tensile strength and good creep resistance
Tungsten has high tensile strength and good creep resistance with a high mass/size ratio, so it will be the ideal to work in a restricted space. Its high density also gives enhanced sensitivity by increasing the control of load distribution.

Machined Easily
WHA is also easily machineable which gives designers greater flexibility in deciding on the final shape of components and offer designers several advantages over conventional balance materials e.g. lead or steel.


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Tungsten alloy ball is small in volume but very dense, which means the product can be used in various fields requiring small but heavy parts, such as the counterweights for golf club, fishing weights, counterweights for military applications, projectiles in the missile weapons, armor piercing ammunition, hunting pellets, prefabricated fragments, the missile weapons, armor piercing ammunition; counterweights for oil logging; also some fields concerning with precision industry, such as mobile phone vibrator, clock cube, self-winding watches, anti-vibration toll holders, flywheel weights, etc. Heavy tungsten alloy balls or tungsten weight is widely used in weight or balance industrial, and in military.

Tungsten alloy ball is in small volume with high density, which means it could be used in some fields need the little but heavy parts, such as the counterweights of golf club, Pinewood Derby car, fishing weights, Medical Instruments, hunting gun’s bullets’ balls; ballast for motorboat, sailboat, submarine; counterweights for military defense, projectiles in the missile weapons, armor piercing ammunition, hunting equipment, prefabricated fragments; counterweights for oil logging; also some fields concerning with precision instrument and shielding material.

Tungsten alloy ball provides a safer, non-toxic and environmentally friendly alternative to lead. Their higher density enables them to hold their shape better, even under extreme conditions.


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With efforts underway to ban lead-based ammunition as a potential health and environmental hazard, scientists are reporting new evidence that a prime alternative material for bullets -- tungsten alloys-- may not be a good substitute The report, which found that tungsten alloys accumulate in major structures of the immune system in animals, appears in ACS' journal Chemical Research in Toxicology.

Jose Centeno and colleagues explain that tungsten alloys have been introduced as a replacement for lead in bullets and other munitions. It resulted from concern that lead from spent ammunition could harm wildlife when it dissolves into water in the soil, streams, and lakes. Scientists thought that tungsten alloys were relatively non-toxic, and a "green" replacement for lead. Recent studies suggested otherwise, and with small amounts of tungsten alloys also used in some artificial hips and knees, Centeno's group decided to gather further information on tungsten alloys.

They added small amounts of  tungsten compound to the drinking water of laboratory mice, used as surrogates for people in such research, and examined the organs and tissues to see exactly where tungsten ended up. The highest concentrations of tungsten were in the spleen, one of the main components of the immune system, and the bones, the center or "marrow" of which is the initial source of all the cells of the immune system. Further research, they say, will be needed to determine what effects, if any, tungsten may have on functioning of the immune system.


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